Truck-Lite LED Headlight installation - Wrist Twisters
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post #1 of 28 Old 04-08-2015, 06:31 AM Thread Starter
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Truck-Lite LED Headlight installation

After reading @marylandmike 's GE LED Headlight install-review, I decided I wanted to do try this


The headlight I used is very similar to the GE unit but is sold by Truck-Lite. The back portion is black instead of gray and the LED holder in the front is also black.

Truck-Lite - Catalog Product : 7'' Round LED Headlamp, Complex Reflector Optics Design

I decided to try a different route after reading that the the standard H6024 light will not fit the OEM 919 mounting hardware. Instead of modifying the headlight, I decided to try another trim ring from an older Honda. I wanted to be able to replace the headlight quickly in case the LED unit failed.

4into1 had exactly what I needed.
7" Chrome Headlight Rim / Retainer Assembly - Honda CB450 CB500 CB550 CB750K

The trim ring fits the 919 bucket size wise, but uses different mounting locations. The 919 ring has a tab on top while the new ring uses a bolt. The side bolts locations on the new ring are a bit more to the front and higher.

I used a Dremel tool to cut off the tab mounting point on the 919 bucket. This allowed the new ring to sit flush inside the bucket. I then drilled a mounting hole on the top of the bucket to accommodate the new ring.
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post #2 of 28 Old 04-08-2015, 06:36 AM Thread Starter
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To secure the trim ring on the headlight bucket, I bought another bolt and spacer from Honda. This allows the ring to fit securely to the bucket without crushing the plastic.

I then slotted the side bolts with the same drill bit I used for the top. Once this is done, the trim ring bolts perfectly to the 919 bucket.

You can now install any 7" round headlight in your 919 bucket.
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post #3 of 28 Old 04-08-2015, 08:31 AM
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Nice work carotman! That upper tab that you cut off. Kept breaking off on mine anyway, so I just left it off. Nice clean install.

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post #4 of 28 Old 04-08-2015, 12:31 PM
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Looks great! Must be a big improvement.

How much is that light? I may be blind but could not see a price on the link that you provided.

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post #5 of 28 Old 04-08-2015, 04:18 PM
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Nice... guess i have another project to do.

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post #6 of 28 Old 04-08-2015, 06:19 PM
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Definitely prefer this over modifying the headlight itself; I'll have to try this once I can finally pick one of these up.
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post #7 of 28 Old 04-08-2015, 06:34 PM Thread Starter
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Quote:
Originally Posted by op_man1 View Post
Looks great! Must be a big improvement.

How much is that light? I may be blind but could not see a price on the link that you provided.
You can get this in almost any auto parts store. I got mine from a friend that works in a truck parts supply. It was a gift so I don't know how much it costs locally.

You can get it on Amazon for a decent price though.

http://www.amazon.com/Truck-Lite-272.../dp/B007K8AA7I

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post #8 of 28 Old 04-08-2015, 06:46 PM
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That's a really decent price. Post a review of the light if you haven't already!

Cheers

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post #9 of 28 Old 04-08-2015, 07:06 PM Thread Starter
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Too cold to ride right now and it's even snowing...

I should be able to test the light next week.

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post #10 of 28 Old 04-08-2015, 07:14 PM
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Quote:
Originally Posted by carotman View Post
Too cold to ride right now and it's even snowing...

I should be able to test the light next week.
I bet you will be pleasantly surprised. I know I was with the GE light which is pretty much the same, especially if you are going from stock.

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post #11 of 28 Old 04-08-2015, 08:29 PM
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Yeah, snowing here too. Nice forecast for the weekend, though.

If I get the $s, this is a definite mod for me in the near future.

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post #12 of 28 Old 04-09-2015, 07:11 AM
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Yeah, I installed the truck-lite on my Monster, the difference is pretty damn fantastic.

I do have one small issue with it, and that's the beam is so focused that when I lean into a turn, the beam dips out of my sight line, which at first was a little disconcerting. It might be due to the headlight angle (Maybe I have it pointed down too much or something), but I noticed that when I had it aimed higher I would get a lot more people flashing me with their lights because they thought my brights were on. Once I lowered it a little the flashing from cars stopped.

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post #13 of 28 Old 05-14-2017, 11:20 AM
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So I followed your steps with a generic headlamp (don't have truck-lite/jw speaker money).

Did pretty well, the Emgo trim ring took some figuring out to attach it to the light, but in the end got it together. Those square nuts were a total pita to stay when attaching the bowl to the trim ring!

I dremeled away those clips, took apart the headlight and ring to use the ring and mark the top hole, drilled the sides up a bit, which sucked a bit, I gouged up one side a bit, and the light looks like it is rotated about 3į off centre



I really do like the look of it. I didn't have anything to solder/hook up the halo yet, but will probably get that on next weekend.



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post #14 of 28 Old 05-19-2017, 08:50 AM Thread Starter
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Glad my instructions helped.

That light looks awesome.

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post #15 of 28 Old 01-26-2018, 06:15 AM
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Quote:
Originally Posted by carotman View Post
To secure the trim ring on the headlight bucket, I bought another bolt and spacer from Honda. This allows the ring to fit securely to the bucket without crushing the plastic.

I then slotted the side bolts with the same drill bit I used for the top. Once this is done, the trim ring bolts perfectly to the 919 bucket.

You can now install any 7" round headlight in your 919 bucket.
Do you know where the spacer and bolt were off of? Thats the only thing i am confused about! Part numbers would be fantastic!

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post #16 of 28 Old 02-09-2018, 11:34 AM Thread Starter
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They are from the 919.

There's already 2 bolts and a 2 spacers on the headlight bucket. I bought a 3rd one and installed it on top of the bucket

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post #17 of 28 Old 03-06-2018, 06:21 AM
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Quote:
Originally Posted by carotman View Post
They are from the 919.

There's already 2 bolts and a 2 spacers on the headlight bucket. I bought a 3rd one and installed it on top of the bucket
Sorry to be a bother. Found a good deal on the truck lite 27270C so i think i am going to be following your DIY to a T.

Still had 2 questions. The hole on the top of the bucket....was the hard to do? Id really hate to mess it up!Im guess you dont know the drill bit size you had to use. Did you have to enlarge the other holes also?

I'm assuming I would need part 18 and 25?

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post #18 of 28 Old 03-06-2018, 05:15 PM
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27270C acquired tonight (Paid 180cdn for it brand new). I ordered the headlight rings (35US).

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post #19 of 28 Old 03-07-2018, 04:17 AM
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You need parts 20 and 25. 18 is the standoff/spacer for mounting the bucket to the brackets.

Drilling the new hole isnít too bad, just find the right size bit for the sleeve, take the top two tabs off the bucket with a Dremel and offer up the headlight ring. I marked it from the inside and then drilled upwards with a small bit, then opened it up with on the right size from the top, put the sleeve in the hole and tested it.

The side holes will need to be made bigger, thatís where my bucket doesnít look too good as I gouged those areas a bit.

If I did mine differently, Iíd put the bike on a paddock stand (or if youíre a lucky one, your centre stand), as I think my light is a little skewed when bolt upright.


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post #20 of 28 Old 03-07-2018, 06:12 AM
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Cleared up everything for me! I'm just wondering if i should use a Dremel or a step bit. Is it mandatory to do the top bucket hole?

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post #21 of 28 Old 03-07-2018, 06:21 AM
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Definitely do the top hole. There wonít be anything holding the headlight at the top otherwise. The tabs at the top of the bucket wonít do a thing for the new headlight ring.

The alternative is to get a different bucket (you can then spare your 919 bucket any modifications), but that may then mean you need new headlight mounts.


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post #22 of 28 Old 03-08-2018, 07:18 AM
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Ive got everything ordered. Pending weather I may get to work on it next week...

It works!

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post #23 of 28 Old 04-09-2018, 03:40 PM
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Thanks carotman. I used the same headlight rim assembly to fit my led headlight. I could use the entire rim assembly since my style of led fitted perfectly. I've got left to right adjustment as well. I used fibreglass to patch original holes in bucket. The fibreglass also reinforced the bucket at these mount points.
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post #24 of 28 Old 04-09-2018, 03:53 PM
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So many eyes :P



Quote:
Originally Posted by Islandboy View Post
Thanks carotman. I used the same headlight rim assembly to fit my led headlight. I could use the entire rim assembly since my style of led fitted perfectly. I've got left to right adjustment as well. I used fibreglass to patch original holes in bucket. The fibreglass also reinforced the bucket at these mount points.

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post #25 of 28 Old 04-09-2018, 04:05 PM
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Ha. All the better to see you with!

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post #26 of 28 Old 09-20-2018, 09:24 AM
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Anybody ever tried to fit the Trucklite 27270CP into a 1986 Honda Shadow? I have that bike and the bucket is to small for this 7 inch light. Is there a different LED light available for this machine? Any help would be good.

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post #27 of 28 Old 09-21-2018, 07:18 AM Thread Starter
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The Shadow uses a 5-3/4" headlight I think.

You will have to use a head light designed for this size . There are quite a few makes available, especially since many Harley Davidson motorcycles use that size.

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post #28 of 28 Old 09-21-2018, 09:57 AM
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Thanks Man! I will look for something else or make a housing adapter. Thanks again!

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